Design And Construction Of Horizontal Axis Wind Pump

© JUL 2019 | IRE Journals | Volume 3 Issue 1 | ISSN: 2456-8880

Design and Construction of Horizontal Axis Wind Pump THAN NAING WIN1, KYAW AUNG2, AUNG KO WIN3, CHO CHO KHAING4 1, 3, 4 Department of Mechanical Engineering, Technological University, Magway, Myanmar 2 Department of Mechanical Engineering, Technological University, Mandalay, Myanmar

Abstract- The purpose of this paper is to provide water supply from wind energy for local area. Wind energy is one the lowest-priced renewable energy technologies available today. The horizontal axis wind pump is designed to derive 48W pump. The blades of wind pump are designed by using the NACA 64-215 series. The multi-blade wind pump can produce 51W. 48W pump can be used with low speed. Blade is divided into 8 elements with equal length forming 9 sections throughout the blade. The blade length is obtained 0.701 m and rotor swept area is 2.5847 m2. Diameter of rotor is 1.8288 m.

The rotor speed is 157 rpm. Therefore, the transmission system is used to get less revolution from output shaft of the wind pump. The speeddown spur gear (315 mm diameter, 5 mm module, face width 0.785 mm and 63 teeth) are used. The design of pinion is 140 mm diameter, 5 mm module, face width 0.785 mm and 30 teeth. Material of spur gear and pinion are selected with cast steel.For utilization of house-hold wind generation, the calculation of rotor swept area and selection for height of tower is the most important factor. The technical data, capacity and testing results of the designed wind pump are also presented.

Indexed Terms- Wind Energy, Pump, Multi-Blade, Gear, Blade I.

INTRODUCTION OF WINDMILL

Windmills are classified as ‘horizontal-axis’ and ‘vertical-axis’ depending upon the orientation of the axis of rotation of their rotors. A wind mill operates by slowing down the wind and extracting a part of it’s energy in the process. For a horizontal axis, the rotor axis is kept horizontal and aligned parallel in the direction of the wind stream. In a vertical-axis turbine, the rotor axis is vertical and fixed, and remains perpendicular to the wind stream. Windmills have blades fixed to a central shaft. The extracted

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energy causes the shaft to rotate. This rotating shaft is used to drive a pump, to grind seeds or to generate electric power. Two important aerodynamic principles are used in windmill operations, i.e. lift and drag. Wind can rotate of a wind mill either by lifting (lift) the blades or by simply passing against the blades (drag).

Slow-speed mills are mainly driven by the drag forces acting on the rotor. The torque at the rotor shaft is comparatively high which is of prime importance for mechanical applications such as water pumps. For slower mills, a greater blade area is required, so the fabrication of blades is undertaken using curved plates.

High speed mills utilize lift forces to move the blades, which phenomenon is similar to what acts on the wings of an aero plane. Faster mills require aero foil-type blades to minimize the adverse effect of the drag forces. The blades are fabricated from aerofoil sections with a high thickness-to-chord ratio in order to produce a high lift relative to drag.

II.

HORIZONTAL AXIS WINDMILL MACHINE

Horizontal axis wind turbines resemble an airplane propeller with either two or three blades. Horizontal axis wind generator may be drag systems. The axis rotation is horizontal and the rotor plane is vertical facing the wind.

The shaft is mounted on two bearing. Blades on rotor is usually designed to be oriented in front (upwind) or behind (downwind) of the tower. Upwind machines need a tail or some other mechanism to maintain orientation. Downwind machines produce wind shadow and turbulence in the blade path. This may be quite seriously affected by the tower.

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© JUL 2019 | IRE Journals | Volume 3 Issue 1 | ISSN: 2456-8880 III.

MAIN COMPONENTS OF WIND PUMP

There are seven main components in the windmill.

These are described as the followings: (i) Rotor (ii) Tail vane (iii) Shaft (iv) Bearing (v) Gear Box (vi) Pump and (vii) Tower.

η0  

output power input power

pump power wind power

511.3 1  ρ  A  u3 2 511.3 0.342  1 1.2  A  53 2 A = 2.5847 m2 Rotor swept area A = 2.5847 m2 πR2 = 2.5847 R = 0.907 m = 2.9757 ft ≈ 3 ft Take hub radius, r = 0.2413 m And following simple formulas are needed: r λr  λ  R 2r c  0.7  cos  B 2 1   tan 1[  ] 3 λr 

β  α Figure.1. Main Components of Wind Pump IV.

DESIGN CALCULATION OF BLADE DESIGN

Mechanical efficiency is 95% for wind machine and pump efficiency is 80%. In practice values of system efficiency commonly range from 10% to 50% although higher and lower values are possible.

Design Specification

The air foil shape is NACA 64-215 type. α can be chosen from Cd/Cl is minimum value , α is 7 degrees and 8 segments.

0.2413  0.7981 0.907 2 1   tan 1[  ]  39.87 3 0.7981 λr  3

β  39.87  7  32.8725 c

2π  0.213  0.7  cos32.8725 0.0495 m 18

Pump power Pp = 51 W Wind speed u = 5 m/s Safety factor = 1.3 Density of air ρ = 1.2 kg/m3 Number of blade B = 18 Power coefficient Cp = 0.45 Tip-speed ratio λ = 3 Overall efficiency η 0 is

Figure 2. Profile and Blade Angle of Various Sections

η0  Cp  ηmech  ηpump  0.45 0.95 0.8 = 0.342

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© JUL 2019 | IRE Journals | Volume 3 Issue 1 | ISSN: 2456-8880 λ=3 Cp = 0.45 The rotor speed = N  60u 2R 60  3  5  2  0.907 = 175.926 rpm The rotor power, PR

 C p Pw

1  C p  ρAu 3 2

1  0.45   1.2  2.5847 53 2 = 87.2336 kW

P  60 2πN 87.2336  = 0.1578 N-m 2π  175.926

Torque, T



Figure 3. Design of Blade Assembly Table 1. Result of blade chords and blade angles Cross Section No.

R (m)

λr

β (deg)

c (m)

39.87

32.8725

0.0495

30.9299

23.9299

0.0751

25.0379

18.0379

0.1002

20.9452

13.9452

0.1248

17.963

10.963

0.1491

15.7059

8.7059

0.1731

13.9421

6.9421

0.1969

12.5288

5.5288

0.2205

ɸ α

1

0.2413

0.7981 7

2

0.3364

1.1126 7

3

0.4315

1.4272 7

4

0.5266

1.7417 7

5

0.6217

2.0563 7

6

0.7168

2.3708 7

7

0.8119

2.6854 7

8

0.907

3 7

Figure 4. Horizontal Axis Wind Pump V.

CALCULATION OF ROTOR SPEED, ROTOR POWER AND TORQUE

Design Data: u = 5 ms-1 R = 2.9757 m ρ = 1.2 kgm-3 A = 2.5847 m2 From Figure 3.3,

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VI.

CALCULATION OF TAIL DESIGN

Design Specification d1 = 0.0889 m (3.5 inch) d2 = 0.7581 m (2.48 ft) Area of rotor AR = 2.5847 m2

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© JUL 2019 | IRE Journals | Volume 3 Issue 1 | ISSN: 2456-8880 = 0.306 m The distance of x is 0.306 m from XX line and the tail vane is 0.93 m from the unit.

A Tail 

d1  2.5847 d2

A Tail 

0.0889  2.5847 0.7581 2

ATail = 0.334 m Take b1 = 0.457 m b2 = 0.3810 m h = 0.6 m Tail vane area is the combination of the trapezium area, A1 and the triangle area, A2.

The total area for tail vane, Atail = A1 + A2  1 h(b1 + b2) + 1 xb2 2 2 0.3031 = {0.5×0.6(0.457+0.3810)} + {0.5×x×0.3810)} 0.3031 = 0.2514 + 0.1905x x = 0.271 m Thus, the height of triangle is 0.271 m.

Figure 5. Center of Gravity of Tail Vane The Center of Gravity of composite Tail Vane (i) For Trapezium, A1 = 0.2514 m2

x1 

h(2b2  b1 ) 0.6(0.762 0.457)  3(0.381 0.457) 3(b2  b1 )

= 0.291 m (ii) From Triangle, A 2  1 xb 2 2 1   0.271 0.38 2 = 0.0516 m2the centroid of triangle,

1 x 2  x 1  x  0.291+ ( 1 × 0.271) = 0.381 m 3 3 x

 xA  (0.291 02514) (0.381 0.0516) (0.2514 0.0516) A

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Table.2. Result Data of Wind Pump Rotor Speed 175.926 rpm Rotor Power 87.2336 kW Torque 0.1578 N-m Area of Tail Vane 0.334 m2 Hub Height 4.572 m Tower Height 4.26 m Tower Type Lattice Tower Blade Length 0.7545 m Rotor Swept Area 2.5847 m2 Number of Blades 18 Blade Material 16 gauge Iron Plate Revolution 157~789 rpm Type Horizontal-Axis Propeller Type Rotor Placing Upwind Rotor Gear Type Speed-down Spur Gear Gear Ratio 1-2.25 Shaft Material Solid Shaft Commercial Steel Bearing Bearing Block Type Reciprocating Piston Type Power 51W Rating 2.4337 L/s at 175.926 rpm Yaw Control Tail Vane Pump Input 51 W Pump Output 48W Pump Efficiency 94% Rated Wind Speed 5 ms-1 Cut-in Wind Speed 4 ms-1 Cut-out Wind 10 ms-1 Speed VII.

CONCLUSION

In the design and construction of wind pump, all materials are selected that are available from the local market. The rotor blades are made by 16 gate iron plate. According to the design result the optimum angle of attack is 7 degrees. The blade length is obtained 0.7547 m and rotor swept area is 2.5847 m2.

The multi-blade wind pump can produce 87.2244 kW. So we can drive 51 W pump. This wind pump can produce 51 W at 5m/s. the rotor speed at 5m/s is 175.926 revolutions per minute. Gear box is required to reduce the shaft revolution.

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Š JUL 2019 | IRE Journals | Volume 3 Issue 1 | ISSN: 2456-8880 [8] J. Helsen, P. Peeters, K. Vanslambrouck, F. To consider tail vane area, practical ratios of vane span to chord are between two and ten. A typical vane might be five times as tall as its width. In this research, the tail vane span to chord ratio is practically 5 times and it is free within 45 degrees inclination. Therefore, tail vane can give power enough. The more van span ratio is within the range, the better it will be.

The power production of Wind Pump increases significantly with height of turbulence. The choice of location and height of wind mill machine should be a synthesis of the wind speed, topography, obstruction, cost and every local status. Application of wind energy for water supply has many different options.

One of them is to build wind farm and provide water supply for rural areas.

Vanhollebeke, and W. Desmet, "The dynamic behavior induced by different wind turbine gearbox suspension methods assessed by means of the flexible multibody technique," Renewable Energy, vol. 69, pp. 336-346, 2014.

[9] A. R. Nejad, Z. Gao, and T. Moan, "Fatigue reliability-based inspection and maintenance planning of gearbox components in wind turbine drivetrains," Energy Procedia, vol. 53, pp. 248257, 2014.

[10] Y. Xing and T. Moan, "Multi�body modelling and analysis of a planet carrier in a wind turbine gearbox," Wind Energy, vol. 16, pp. 1067-1089, 2013.

REFERENCES

[1] Perk.Jeck. 1982. The wind power book. U.S.A [2] Kothari, D.P, Signal, K.C and Rakesh Ranjan.

2008. Renewable Energy Sources and Emerging Technologies, New Delhi.

[3] A. Heege, Y. Radovcic, and J. Betran, "Fatigue load computation of wind turbine gearboxes by coupled structural, mechanism and aerodynamic analysis," dEWI Magazin, vol. 28, pp. 61-68, 2006.

[4] Youtube

video v=03VMxlazPJU

https://m.youtube.com/watch?

[5] Machini N. Mercyline, Okero Julius Mokaya.

2009. Mechanical and Manufacturing Engineering, University of Nairobi.

[6] L. C.-f. ZHOU Shi-hua, WANG Kai-yu, WEN Bang-chun, "Dynamic Model of the Transmission System in Wind Turbine Gearbox," Journal of Northeastern University (Natural Science), vol.

35, pp. 1301-1305, 2014.

[7] J. Helsen, G. Heirman, D. Vandepitte, and W. Desmet, "The influence of flexibility within multibody modeling of multi-megawatt wind turbine gearboxes," in Proceedings of the ISMA International Conference on Noise & Vibration Engineering, 2008, pp. 2045-2071.

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